I saw some homemade flip flops in this forum before, but I couldn't find the thread. Anyway, they were made from insoles and were roundly criticized for not offering enough protection.

I had a hunk of Wal-Mart pad lying around from when I cut my summer pad to 3/4 length. From that I made a pot cozy and these camp slippers. They weigh 1.25 oz. each. Around the house and in the yard they've been exceptionally comfortable. The pad is much softer (and lighter) than store bought flip flops which weigh in at 8.5 oz. I'll post again when I've tested them in camp.

If you are trying to MYOG, and if you don't like the flip-flop piece between your toes, then make them with the alternative sandal style. This has flat straps that velcro fasten around the ankle and one goes across the top of the toes. You can find a few of them in the stores.

The "protection" they were referring to was from stones. Insoles are pretty thin, so the stones can be felt through them, sometimes painfully.

Frankly, I'd prefer the sandal alternative too, I just didn't have any idea how to approach the task. I didn't have a lot of spare pad material, so I wanted to get something that would work the first try. I hope you post your final sandal design.

I think you'll enjoy them. For light weight AND comfort, I haven't found anything that comes close.